Paper yarn



Sept. 17, 1946. K. HAMILTON PAPR YARN Filed Feb. 7', 1945 ATTORNEY;

Patented Sept. 17, 1946 STATES PATENT OFFICE PAPER YARN Kenneth Hamilton, Amsterdam, N. TY., assigner to vMohawk vCarpet Mills, Inc., Amsterdam, N. Y., a corporation of New York Application February 7, 1945, Serial No. 576,669

7 Claims.

l This-invention `relates'to strands which are made bytwisting a narrow strip of paper about its longitudinal axis andare variously referred to -as-paper yarn, cord, twine, etc. More particularly, the invention is concerned with a novel paper yarn having characteristics which make it superior to `prior similar yarns for certain purposes, and with a method and apparatus by which the new yarn may be readily produced at low cost.

Paper yarn has been manufactured and used fintheproductionof textile fabrics for some time,

and, for some purposes, such yarn is generally acceptable, `As made heretofore, the yarn is quite stiff Vand wiry and it can thus be employed to advantage for the stuffer warps in pile fabrics used for floor coverings, in that the yarn gives lbody to the fabric and stiffens it so that it will yarn, as a result of which it can not readily be lbent sharply and is subject to kinking. When inserted ina shed by a needle or a shuttle, the yarn overruns, so that loose loops are formed at the edges of the fabric and the selvages are unsatisfactory. `Kinking of the yarn produces imperfections in the fabric, as, for example, in pile fabrics, a kink in the filling may cause separation ofthe pile tufts, so that the pile appears to have spaces from which the tufts are missing. The

prior yarn may be readily made flexible enough to avoid the diiculties above mentioned by wetting it, but when that is done, the yarn becomes so weak that it breaks frequently during the weaving operation.

The present invention is, accordingly, directed to the provision of a paper yarn, whichis both sufficiently flexible to permit its insertion as weft in a fabric made on either a needle loom or a shuttle loom, and sufficiently strong to enable it to withstand the strains to which it is subjected in weaving without being broken. Thenew yarn, once incorporated in a fabric, may be readily 4modified to give it the stiffness of prior paper yarn so that it will impart the desired stiffness and body to the fabric.

The new yarn differs from ordinary paper 'yarns'in-that Vit contains moisture in its interior,

`tional methods.

, 2 so that it is flexible, and it is `providedron its outer surface with a thin flexible substantially continuous film or coating that is impenetrable by moisture. The coating serves to retain `the moisture in the interior of the yarn,so that the `yarn remains'exible indefinitely, while the coating is in place. The coating serves the further purpose of adding to the Wet strength of the yarn, `so that the moist exible yarn, which .would otherwise be too weak for satisfactory use in weaving, may be readily woven into fabrics without being broken. The coating is: preferably made of a material whichis volatile at elevated temperatures, and, when such amaterialis used, the coating remains in place under ordinary conditions but can bel driven ofi by heat,I so that the yarn will then dry out and become sti', asdesired. The coating may advantageously bevmade of a material having lubricating qualities, and a coating of sucha material enables the yarn to pass readily through and around guides withf outwear.

The new yarn'may be made in various ways, as, for example, a strip of paper of thedesired width andweight may be formed into yarn by conven- The `yarn may then be treated to cause it to take up the moisture required `to make it flexible, after which it may be given the coating which retains the moisture and increases the wet strength of the yarn. Preferably, however, the paper is moistened prior to the forming and twisting operations and the coating is applied after the yarn has been partially formed and before the twisting is completed. By this method, the number of operations in the production of the new yarn is reduced and a better product results, since during the completion of the twisting, the coating material is distributed on the surface of the yarn to Vform a continuous `external layer.

For a better understanding of `the invention, 4reference may be made to the accompanying drawing, in which y Fig. 1 illustrates diagrammatically lapparatu used in the production of thenew yarn according to the method of the invention;

Fig. 2 is a sectional View on the line 2-2 o Fig. `1;

Fig. 3 is a longitudinal sectional View througha part of the apparatus; and

Fig. 4 is a perspective view of the new yarn on an enlarged scale, the yarn beingshown partly in cross-section.

The new yarn is made of a strip lll of a suitable paper, I,suchlas akraiTt-papeLandthe ,width ofpthe `strip is condensed and crushed together.

strip and the weight of the paper stock are chosen to give the yarn the desired size and strength. In the production of the yarn, the strip is drawn from a roll I I and rst moistened. For this purpose, it may be passed beneath a guide I2 and then over and in contact with a roller I3 partially immersed in liquid I4 in a vessel I5. The liquid usedA Vis water to which preferably, a small amount, such as from 1% to 5%, of wool oil has been added in emulsion form. The moistening agent may also include a small amount of a penetrant. In the moistening operation, the paper takes up about 25% of its weight in moisture and it becomes highly flexible but is weakened.

'Ihe moistened strip passes Afrom the moistening device through a condensing device, which may appropriately take the for-m of a trumpet I 5. This trumpet has a discharge orice I'I of substantially less diameter than the width of the strip and in its passage lthrough the trumpet, the The condensing of the strip may produce random folds extending generally lengthwise and, if desired,

the strip may have its edges turned in, before it is fthreaded through the trumpet.

The condensed strip issuing from the trumpet -then passes between upper and lower compressing rolls I8, I9. Roll I8 is formed with a circumferential channel I8a and roll I9 is formed with a circumferential rib IBa which enters channel I8a. y The bottom of the channel and the peripheral edge of the rib are shaped to define a circular orice through which lthe strip passes for further condensation. Roll I9 is mounted on a Vdriven shaft 20 in fixed bearings and roll I8 is mounted for floating movement. A weighting roll 2| rests freely on roll I8 and serves to press it toward roll 20. l

The condensed strip emerging from between rolls I8, I9 is next given a coating of a material which is impenetrable by moisture, and thus serves to retain the moisture inthe finished yarn `as well as to strengthen the yarn. Various mate- 22 mounted on a shoulder 23 on `a stud 24 lbolted e to the end of a bracket 25. Disc 22 is free t0 rotate on the shoulder and a block 26 of coating material is mounted on the stud for rotation and forced toward the flat convex face of the disc by a light spring 2l. The spring is anchored at one endon the stud and -at its other end bears against a plate resting on the outer face of block 26. The bracket 25 may be mounted in any appropriate manner and, in the construction shown, itis attached to an arm 29 formed withran opening at one end, in which is mounted a porcelain guide 36. Arm 29 is pivoted at 3I on any suitable support and can be swung upwardly in a clockwise direction about its pivot.

The condensed strip issuing from between rolls I8, I9 passes between the flat convex face of disc 22 and the body of coating material. The center of stud 24 is aligned with the oricejdefined by rolls I8, I9, but the diameter of the stud is such that the -strand is forced slightly out of its norf DIODBI manner.

mal path of travel between the orice and guide 30 and is thus kept taut. The movement of the strand between the disc and the block of coating material causes the later to rotate so that fresh surfaces on the block are continuously brought into contact with the strand.

Beyond the coating device, the strip passes through guide 30 and thence to a conventional twisting and winding mechanism. As illustrated, this mechanism includes a traveler 32 mounted for free movement about a ring 33 which is mounted for vertical movement with reference to a spool 34 on spindle 35. For this purpose, ring 33 may be supported on vertical shafts 35 actuated by cams to raise'and lower the ring in the The spindle is supported for rotation in suitable bearings (not shown) and is provided with a pulley 31 about which is trained a belt 38 for rotating the spindle and spool. In the operation of the mechanism, the drag of the traveler results in the twist being imparted to the strip as it is wound on ithe spool. The twist runs backwardly from the traveler up to the guide 30 and through the coating apparatus to the orifice defined by rolls I8, I9. Between the orifice and guide 30, the strip is only partially twisted and the coal-ting material is thus applied before the twisting is completed.

In the finished yarn, the paper forming the interior of the yarn, as indicated at 39, contains the moisture that the paper has picked up. The outer surface of the yarn is provided with a thin coating 40 of material derived from the block 25 and it is found in practice, when paraffin is used, that the coatingv amounts to about 1% by weight of the yarn. At the time of lthe application of the coating to the partially twisted strip, the strip has crevices in its surface into which the coating does not always penetrate. However, as the twisting is completed, the surface areas on the partially twisted strip that have received the coating are brought together, so that ,the layer of coating material becomes substantially continuous over the entire outer surface of Ythe yarn.

The application of the coating material servesv t0 retain |the moisture that has been picked up vby the paper and, because of the presence of the moisture, the new yarn is highly flexible, so that it can be readily used as filling in the weaving vof fabrics. The new yarn will make sharp bends and can be easily conducted through guides, the f that the yarn runs smoothly through and around guides without causing wear thereof. Because of its flexibility; increased wet strength, and the lubricating quality olf its surface, alighter weight of ,the new yarn may be used as filling inthe weaving operation than would be otherwise requiredji After the new yarn has beennished, it may be stored for indefinite periodsbefore use, and it retains its flexibility and strength during such storage. If the yarn were not provided with the coating, the moisture on it would evaporate in the course of time, and, as the yarn dried out, it wouldbecome f stili.v The moisture` originally present would also be likely to cause it to mildew or to become locally weakenedbecause-of uneven wiry, like ordinary paper yarn, by removal of the coating. For this purpose, it is only necessary to subject the fabric to heat which will volatilize the coating and dry out the yarn. In the finishing of most pile fabrics, it is customary to apply sizing to the back and then to pass the sized fabric through a dryer. In the heating incident to the drying of the sizing in the usual way, the coating is removed from the new yarn and the paper is dried out so that the yarn assumes the desired stiffness.

The production of the new yarn in accordance with the methodv described Oilers various advantages, in that the application of moisture and the coating is carried on as an incident to the production of the yarn and requires only minor additions to the usual equipment. Also, the application of the coating to the partially twisted strip insures that the finished yarn will have a coating which is substantially continuous. It is to be understood, however, that the new yarn may be made by other methods and, also, that conventional yarn may be converted to the new yarn, if desired. Thus, the strip may be converted into yarn by ordinary methods and the finished yarn may then be moistened and co'ated in a separate operation. As the finished yarn is tightly twisted, it is difficult to impart to it the desired moisture content, but this can be done by passing the yarn through a bath for a sufficient length of time, or placing the yarn packages in a moist atmosphere. After the yarn has taken up sufficient moisture to make it flexible, it may be coated, for example, by means of the coating device disclosed. The molstening and coating carried on in operations independent of the formation of the yarn involve the use of additional equipment and labor, but, even so, the conversion of the ordinary stiff, wiry yarn to the new yarn may be advantageous, particularly for the owner of a considerable stock of the conventional yarn.

I claim:

1. A yarn which comprises a strip of paper containing a substantial quantity of water distributed throughout the paper, the strip being formed with random generally longitudinal folds and twisted about its longitudinal axis, and a substantially continuous coating impenetrable by water covering the outer surface of the twisted strip, the water within the paper making the twisted coated strip flexible and the coating both adding to the wet strength of the twisted strip and preventing the escape of water therefrom.

2. A yarn which comprises a strip of paper containing a substantial quantity of water distributed throughout the paper, the strip being formed with random generally longitudinal folds and twisted about its longitudinal axis, and a thin substantially continuous coating impenetrable by water covering the outer surface of the twisted strip, the water within the paper making the twisted coated strip flexible and the coating adding to the wet strength of the twisted strip, preventing escape of the water from the paper,

and being made of a material having lubricating qualities.

3. A yarn which comprises a strip of paper containing a substantial quantity of water distributed throughout the paper, the strip being formed with random generally longitudinal folds and twisted about its longitudinal axis, and a thin substantially continuous coating of a waxy material covering the outer surface of the twisted strip, the water within the paper making the twisted coated strip flexible and the coating being impenetrable by water and preventing the escape of the water from the paper and also adding to the wet strength of the twisted strip.

4. A yarn which comprises a strip of paper containing a substantial quantity of water and a less amount of oil, the water and oil being distributed throughout the paper, and the strip being formed with random generally longitudinal folds and twisted about its longitudinal axis, and a substantially continuous coating impenetrable by water and unaffected by the said oil covering the outer surface of the strip, the water and oil within the paper making the twisted coated strip flexible and the coating both adding to the wet strength of the twisted strip and preventing escape of moisture therefrom.

5. A yarn which comprises a strip of paper containing a substantial quantity of water of the order of about 25% of the weight of the paper, the water being distributed throughout the paper and the strip being formed with random generally longitudinal folds and twisted about its longitudinal axis, and a substantially continuous flexible coating of a substance insoluble in water and volatile at elevated temperatures covering the outer surface of the twisted strip, the water within the paper making the twisted coated strip ilexible and the coating both adding to the Wet strength of the twisted strip and preventing the escape of water therefrom.

6. A yarn which comprises a strip of' paper containing a substantial quantity of water distributed throughout the paper, the strip being longitudinally folded and twisted about its longitudinal axis, and a substantially continuous coating impenetrable by water covering the outer surface of the twisted strip, the water within the paper making the twisted coated strip flexible and the coating both adding to the wet strength of the twisted strip and preventing the escape of water therefrom.

7. A yarn which comprises a strip of paper containing a substantial quantity of water distributed throughout the paper, the strip being longitudinally folded and twisted about its longitudinal axis, and a thin substantially continuous coating impenetrable by water covering the outer surface of the twisted strip, the water within the paper making the twisted coated strip ilexible and the coating adding to the wet strength of the twisted strip, preventing escape of the water from the paper, and being made of a material having lubricating qualities.

KENNETH HAMILTON. 

